Furniture system and related methods

ABSTRACT

A leg includes an outer surface, an inner surface, a first wall, a second wall, a first seam, and a second seam. The inner surface is opposite the outer surface. The first wall extends from the outer surface to the inner surface. The second wall is coupled to the first wall and extends from the outer surface to the inner surface. The first seam is formed in the inner surface. The second seam is spaced apart from the first seam and formed in the inner surface. The second seam forms a first non-parallel angle with the first seam and a second non-parallel angle with the first wall.

CROSS REFERENCE TO RELATED APPLICATIONS

This U.S. patent application is a continuation-in-part of U.S. patent application Ser. No. 16/233,669, filed on Dec. 27, 2018, which is a divisional of U.S. patent application Ser. No. 15/657,390, filed on Jul. 24, 2017, which is a continuation-in-part of U.S. patent application Ser. No. 15/407,921, filed on Jan. 17, 2017, now U.S. Pat. No. 10,034,543, issued on Jul. 31, 2018. The disclosures of these prior applications are considered part of the disclosure of this application and are hereby incorporated by reference in their entireties.

FIELD

The present disclosure relates to a system and method for constructing an article, and more particularly to articles having a folded construct.

BACKGROUND

This section provides background information related to the present disclosure and is not necessarily prior art.

Laminated substrates are often used to manufacture various types of furniture and fixtures for homes and offices. For example, countertops, drawer boxes, speaker boxes, and other items are often manufactured from wood, or a wood composite, having a polymer laminate.

While known systems and methods for constructing articles such as bed rails, ceiling panels, and furniture legs have proven useful for their intended purposes, a need for continuous improvement in the pertinent art remains.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

One aspect of the disclosure provides a leg. The leg includes an outer surface, an inner surface, a first wall, a second wall, a first seam, and a second seam. The inner surface is opposite the outer surface. The first wall extends from the outer surface to the inner surface. The second wall is coupled to the first wall and extends from the outer surface to the inner surface. The first seam is formed in the inner surface. The second seam is spaced apart from the first seam and formed in the inner surface. The second seam forms a first non-parallel angle with the first seam and a second non-parallel angle with the first wall.

This aspect may include one or more of the following optional features. In some implementations, the first non-parallel angle is equal to the second non-parallel angle. The first non-parallel angle may be five degrees.

In some implementations, the inner surface defines a multi-sided pyramidal shape.

In some implementations, the first seam includes a first proximal portion and a first distal portion extending from the first proximal portion, and wherein the first proximal portion forms a third non-parallel angle with the first distal portion. The second seam may include a second proximal portion and a second distal portion extending from the second proximal portion. The second proximal portion forms a fourth non-parallel angle with the second distal portion. The outer surface may include a proximal outer portion and a distal outer portion. The proximal outer portion may extend between the first proximal portion and the second proximal portion. The distal outer portion may extend between the proximal outer portion, the first distal portion, and the second distal portion. The proximal outer portion may form a fifth non-parallel angle with the distal outer portion. The proximal outer portion may define a pyramidal cross-sectional shape. The distal outer portion may define a shape having a uniform cross-sectional area.

In some implementations, the outer surface defines a pyramidal shape.

Another aspect of the disclosure provides a leg extending from a proximal end to a distal end. The leg may include a first wall, a second wall, a first seam, a second seam, and an outer surface. The first wall may extend from the proximal end to the distal end. The second wall may be coupled to the first wall and extend from the proximal end to the distal end. The first seam may be spaced apart from the first wall and the second wall and extend from the proximal end to the distal end. The second seam may be spaced apart from the first seam, the first wall, and the second wall and extend from the proximal end to the distal end. The outer surface may include a first segment extending between the first wall and the first seam, a second segment extending between the first seam and the second seam, and a third segment extending between the second seam and the second wall. The first segment, the second segment, and the third segment may define a pyramidal cross-sectional shape extending from the proximal end to the distal end.

This aspect may include one or more of the following optional features. In some implementations, the second seam forms a first non-parallel angle with the first seam and a second non-parallel angle with the first wall. The first non-parallel angle may be equal to the second non-parallel angle. The first non-parallel angle may be five degrees.

In some implementations, the leg includes an inner surface opposite the outer surface and defining a multi-sided pyramidal shape.

In some implementations, the first seam includes a first proximal portion and a first distal portion extending from the first proximal portion. The first proximal portion may form a first non-parallel angle with the first distal portion. The second seam may include a second proximal portion and a second distal portion extending from the second proximal portion. The second proximal portion may form a second non-parallel angle with the second distal portion. The outer surface may include a first distal outer portion extending from the first segment, a second distal outer portion extending from the second segment, and a third distal outer portion extending from the third segment. The first segment may form a third non-parallel angle with the first distal outer portion. The first, second, and third distal outer portions may define a shape having a uniform cross-sectional area.

Yet another aspect of the disclosure provides a leg. The leg may include a substrate having a first proximal segment, a second proximal segment, and a third proximal segment. The second proximal segment may be hingedly coupled to the first proximal segment along a first seam. The third proximal segment may be hingedly coupled to the second proximal segment along a second seam. The first seam may form a first non-parallel angle with the second seam.

This aspect may include one or more of the following optional features. In some implementations, the first proximal segment is coupled to the third proximal segment along a third seam forming a second non-parallel angle with the second seam. The first non-parallel angle may be equal to the second non-parallel angle. The first non-parallel angle may be five degrees.

In some implementations, the first proximal segment includes a first proximal outer surface. In some implementations, the second proximal segment includes a second proximal outer surface. In some implementations, the third proximal segment includes a third proximal outer surface. The first, second, and third proximal outer surfaces may define a varying cross-sectional area. The varying cross-sectional area may define a pyramid.

In some implementations, the leg includes a first distal segment, a second distal segment, and a third distal segment. The first distal segment may be hingedly coupled to the first proximal segment and include a first distal wall and a second distal wall parallel to the first distal wall. The second distal segment may be hingedly coupled to the second proximal segment and include a third distal wall and a fourth distal wall parallel to the third distal wall. The third distal segment may be hingedly coupled to the third proximal segment and include a fifth distal wall and a sixth distal wall parallel to the fifth distal wall. The first distal wall may be coupled to the sixth distal wall. The second distal wall may be coupled to the third distal wall. The fourth distal wall may be coupled to the fifth distal wall. The first distal segment may include a first distal outer surface. The second distal segment may include a second distal outer surface. The third distal segment may include a third distal outer surface. The first, second, and third distal outer surfaces may define a uniform cross-sectional area. The uniform cross-sectional area may define a rectangle. In some implementations, the leg includes a polyurethane adhesive disposed between the first distal segment and the first proximal segment. In some implementations, the leg includes endcap coupled to one or more of the first distal segment, the second distal segment, or the third distal segment, such that the endcap, the first distal segment, the second distal segment, and the third distal segment define an enclosed leg.

In some implementations, the substrate include a base layer and a laminate layer. The base layer may define a channel.

In some implementations, the first proximal segment is coupled to the third proximal segment along a third seam forming a second non-parallel angle with the first seam.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a furniture unit in accordance with the principles of the present disclosure;

FIG. 2 is an exploded view of the furniture unit of FIG. 1;

FIG. 3 is a top view of the furniture unit of FIG. 1;

FIG. 4A is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 4B is an exploded view of the shelf of FIG. 4A;

FIG. 5 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 6 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 7A is a top view of a substrate prior to forming a shelf for use with the furniture unit of FIG. 1;

FIG. 7B is an end view of a shelf formed with the substrate of FIG. 7A and for use with the furniture unit of FIG. 1;

FIG. 7C is a top view of a substrate prior to forming a ceiling baffle;

FIG. 7D is a perspective view of a ceiling baffle formed with the substrate of FIG. 7C;

FIG. 8 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 9 is an end view of a shelf for use with the furniture unit of FIG. 1;

FIG. 10 is an end view of a bedrail in accordance with the principles of the present disclosure;

FIG. 11 is an end view of another bedrail in accordance with the principles of the present disclosure;

FIG. 12 is an end view of another bedrail in accordance with the principles of the present disclosure;

FIG. 13A is a perspective view of a bedrail assembly in a partially assembled state in accordance with the principles of the present disclosure;

FIG. 13B is a perspective view of the bedrail assembly of FIG. 13A in an assembled state in accordance with the principles of the present disclosure;

FIG. 14A is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 14B is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 14C is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 14D is cross-sectional view of a substrate during a method of manufacturing the furniture unit of FIG. 1;

FIG. 15 is a perspective view of another furniture unit in accordance with the principles of the present disclosure;

FIG. 16 is a side view of a leg, for use with the furniture unit of FIG. 15, in accordance with the principles of the present disclosure;

FIG. 17 is a cross-sectional view of the leg of FIG. 16, taken along the line 17-17;

FIG. 18 is a cross-sectional view of the leg of FIG. 16, taken along the line 18-18;

FIG. 19 is a plan view of a substrate prior to forming the leg of FIG. 16;

FIG. 20 is a plan view of a substrate during a method step of forming a leg for use with the furniture unit of FIG. 15, in accordance with the principles of the present disclosure;

FIG. 21 is a plan view of the substrate of FIG. 20 during another method step of forming a leg for use with the furniture unit of FIG. 15, in accordance with the principles of the present disclosure;

FIG. 22 is a side view of the substrate of FIG. 20 during another method step of forming a leg for use with the furniture unit of FIG. 15, in accordance with the principles of the present disclosure; and

FIG. 23 is a side view of another leg, for use with the furniture unit of FIG. 15, in accordance with the principles of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

With reference to FIGS. 1-3, a furniture unit 10 is provided. While the furniture unit 10 is generally shown and described herein as being a bookcase, it will be appreciated that the furniture unit 10 (e.g., shelves, legs, backer, etc.), or parts thereof, may include, or otherwise be utilized as, other types of home or office furniture or fixtures (e.g., tables, bed frames, desks, doors, ceiling panels, ceiling baffles, etc.) within the scope of the present disclosure.

The furniture unit 10 may include one or more shelf sections 12-1, 12-2, . . . 12-n, one or more connectors 14-1, 14-2, . . . 14-n, and one or more caps 16-1, 16-2, . . . 16-n. Each shelf section 12-1, 12-2, . . . 12-n may include a shelf 18, a lateral leg 20, a medial leg 22, and a backer 24. The shelf 18 may extend from a lateral end 26 to a medial end 28 opposite the lateral end 26. The lateral leg 20 may be coupled to, or otherwise supported by, the lateral end 26 of the shelf 18. The medial leg 22 may be coupled to, or otherwise supported by, the medial end 28 of the shelf 18. As illustrated in FIG. 3, the backer 24 may be coupled to, or otherwise supported by, the shelf 18, the lateral leg 20, and/or the medial leg 22.

As illustrated in FIG. 2, the lateral and medial legs 20, 22 may each define a substantially hollow construct having upper and lower openings 30, 32. The upper and lower openings 30, 32 may define any of a variety of shapes. For example, while the upper and lower openings 30, 32 are generally illustrated as defining rectangular (e.g., square) shapes, it will be appreciated that the upper and lower openings may define another shape such as a triangle, a circle, or another polygon within the scope of the present disclosure. In some implementations, the lateral and/or medial leg 20, 22 may include the shelf 18, or a construct substantially similar thereto. For example, the lateral leg 20 may define another shelf, substantially similar or identical to shelf 18, supported by the lateral end 26 of the shelf 18, and the medial leg 22 may define another shelf, substantially similar or identical to shelf 18, supported by the medial end 28 of the shelf 18.

With further reference to FIG. 2, the connectors 14-1, 14-2, . . . 14-n may each include a first coupling portion 34, a second coupling portion 36, and a stop portion 38. The first and second coupling portions 34, 36 may define any of a variety of shapes. For example, while the first and second coupling portions 34, 36 are generally illustrated as defining rectangular (e.g., square) shapes, it will be appreciated that the first and second coupling portions 34, 36 may each define another shape such as a triangle, a circle, or another polygon within the scope of the present disclosure. In this regard, the size and shape of the first and second coupling portions 34, 36 may correspond to the size and shape of one or both of the upper or lower openings 30, 32 of the lateral and medial legs 20, 22, such that the upper or lower openings 30, 32 can receive the first or second coupling portions 34, 36 of the connectors 14-1, 14-2, . . . 14-n in an assembled configuration, as described in more detail below.

The stop portion 38 may extend outwardly from, or otherwise relative to, the first or second coupling portions 34, 36 of the connectors 14-1, 14-2, . . . 14-n. In some implementations, the stop portion 38 defines an outwardly extending flange relative to the first and second coupling portions 34, 36. In this regard, the stop portion 38 may define a shape that is substantially similar to the shape defined by the first or second coupling portions 34, 36.

The caps 16-1, 16-2, . . . 16-n may each include a coupling portion 40 and a stop portion 42. The coupling portion 40 may define any of a variety of shapes. For example, while the coupling portion 40 is generally illustrated as defining a rectangular (e.g., square) shape, it will be appreciated that the coupling portion 40 may define another shape such as a triangle, a circle, or another polygon within the scope of the present disclosure. In this regard, the size and shape of the coupling portion 40 may correspond to the size and shape of one or both of the upper or lower openings 30, 32 of the lateral and medial legs 20, 22, such that the upper or lower openings 30, 32 can receive the coupling portion 40 of the caps 16-1, 16-2, . . . 16-n in an assembled configuration, as described in more detail below. The stop portion 42 may extend outwardly from, or otherwise relative to, the coupling portion 40 of the caps 16-1, 16-2, . . . 16-n. In some implementations, the stop portion 42 defines an outwardly extending flange at, and relative to, an uppermost portion of the coupling portion 40. In this regard, the stop portion 42 may define a shape that is substantially similar to the shape defined by the coupling portion 42.

As illustrated in FIGS. 1 and 2, in the assembled configuration, the shelf sections 12-1, 12-2, . . . 12-n may be arranged in a stacked configuration. In this regard, the lateral leg 20 of the first shelf section 12-1 may be removably coupled to the lateral leg 20 of the second shelf section 12-2, and the medial leg 22 of the first shelf section 12-1 may be removably coupled to the medial leg 22 of the second shelf section 12-2. For example, one or more connectors 14-1, 14-2, . . . 14-n may be removably coupled to the lateral leg 20 of the first shelf section 12-1 and to the lateral leg 20 of the second shelf section 12-1, and another one or more connectors 14-1, 14-2, . . . 14-n may be removably coupled to the medial leg 22 of the first shelf section 12-1 and to the medial leg 22 of the second shelf section 12-1. In particular, the first coupling portion 34 of one or more of the connectors 14-1, 14-2, . . . 14-n may be disposed within one or more of the upper openings 30 of the lateral leg 20 of the first shelf section 12-1, and the second coupling portion 36 may be disposed within one or more of the lower openings 32 of the lateral leg 20 of the second shelf section 12-2, such that the stop portion 38 engages the lateral legs 20 of the first and second shelf sections 12-1, 12-2. Similarly, the first coupling portion 34 of one or more of the connectors 14-1, 14-2, . . . 14-n may be disposed within one or more of the upper openings 30 of the medial leg 22 of the first shelf section 12-1, and the second coupling portion 36 may be disposed within one or more of the lower openings 32 of the medial leg 22 of the second shelf section 12-2, such that the stop portion 38 engages the medial legs 22 of the first and second shelf sections 12-1, 12-2.

With reference to FIGS. 4A and 4B, the shelf 18 may include, or otherwise be formed from, a substrate 46 having a layered construct. In this regard, the substrate 46 may include a base layer 48, an upper laminate layer 50, and a lower laminate layer 52. The base layer 48 and the upper and lower laminate layers 50, 52 may each be formed from one or more of a variety of materials. In some implementations, the base layer 48 is formed from a medium-density fiberboard material, a polymer material (e.g., polyvinyl chloride), or a particle board material, and the laminate layers 50, 52 are formed from a paper material or a polymer material (e.g., polypropylene).

The base layer 48 may include an upper surface 54, a lower surface 56 opposite the upper surface 54, and a peripheral surface 58. The upper and lower surfaces 54, 56 may extend from a proximal portion 60 of the substrate 46 to a distal portion 62 of the substrate 46. The peripheral surface 58 may extend from the upper surface 54 to the lower surface 56. In this regard, the peripheral surface 58 may include a proximal peripheral surface 64, a distal peripheral surface 66, a lateral peripheral surface 68, and a medial peripheral surface 70. The proximal peripheral surface 64 may be disposed in the proximal portion 60 of the substrate 46. The distal peripheral surface 66 may be disposed in the distal portion 62 of the substrate 46 opposite the proximal peripheral surface 64. The lateral peripheral surface 68 may extend from the proximal peripheral surface 64 to the distal peripheral surface 66. The medial peripheral surface 70 may extend from the proximal peripheral surface 64 to the distal peripheral surface 66 opposite the lateral peripheral surface 68.

The upper laminate layer 50 may include an upper surface 74, a lower surface 76 opposite the upper surface 74, and a peripheral surface 78. The upper and lower surfaces 74, 76 may extend from the proximal portion 60 of the substrate 46 to the distal portion 62 of the substrate 46. The peripheral surface 78 may extend from the upper surface 74 to the lower surface 76. In this regard, the peripheral surface 78 may include a proximal peripheral surface 80, a distal peripheral surface 82, a lateral peripheral surface 84, and a medial peripheral surface 86. The proximal peripheral surface 80 may be disposed in the proximal portion 60 of the substrate 46. The distal peripheral surface 82 may be disposed in the distal portion 62 of the substrate 46 opposite the proximal peripheral surface 80. The lateral peripheral surface 84 may extend from the proximal peripheral surface 80 to the distal peripheral surface 82. The medial peripheral surface 86 may extend from the proximal peripheral surface 80 to the distal peripheral surface 82 opposite the lateral peripheral surface 84.

The lower laminate layer 52 may include an upper surface 88, a lower surface 90 opposite the upper surface 88, and a peripheral surface 92. The upper and lower surfaces 88, 90 may extend from the proximal portion 60 of the substrate 46 to the distal portion 62 of the substrate 46. The peripheral surface 92 may extend from the upper surface 88 to the lower surface 90. In this regard, the peripheral surface 92 may include a proximal peripheral surface 94, a distal peripheral surface 96, a lateral peripheral surface 98, and a medial peripheral surface 100. The proximal peripheral surface 94 may be disposed in the proximal portion 60 of the substrate 46. The distal peripheral surface 96 may be disposed in the distal portion 62 of the substrate 46 opposite the proximal peripheral surface 94. The lateral peripheral surface 98 may extend from the proximal peripheral surface 94 to the distal peripheral surface 96. The medial peripheral surface 100 may extend from the proximal peripheral surface 94 to the distal peripheral surface 96 opposite the lateral peripheral surface 98.

In the assembled configuration, the upper surface 54 of the base layer 48 may engage the lower surface 76 of the upper laminate layer 50, and the lower surface 56 of the base layer 48 may engage the upper surface 88 of the lower laminate layer 52, such that the upper surface 74 of the upper laminate layer 50, the lower surface 90 of the lower laminate layer 52, the peripheral surface 58 of base layer 48, the peripheral surface 78 upper laminate layer 50, and the peripheral surface 92 of lower laminate layer 52 define outermost surfaces of the substrate 46. In some implementations, the upper surface 54 of the base layer 48 may be bonded to the lower surface 76 of the upper laminate layer 50 using an adhesive or other suitable technique, and the lower surface 56 of the base layer 48 may be bonded to the upper surface 88 of the lower laminate layer 52 using an adhesive or other suitable technique. While the substrate 46 is generally shown and described herein as including the base layer 48, the upper laminate layer 50, and the lower laminate layer 52, the substrate 46 may include the base layer 48 and one of the upper and lower laminate layers 50, 52 within the scope of the present disclosure. In this regard, in some implementations, the upper surface 54 or the lower surface 56 of the base layer 48 may define an outermost surface of the substrate 46.

As illustrated in FIG. 4A, the shelf 18 may include, or otherwise define, a first seam 104-1, a second seam 104-2 spaced apart from the first seam 104-1, and a third seam 104-3 spaced apart from the first and second seams 104-1, 104-2. It will be appreciated that the shelf 18 may include more or less than three seams within the scope of the present disclosure. For example, as illustrated in FIG. 4A, in some implementations, the shelf 18 may include first, second and third seams 104-1, 104-2, 104-3 in the proximal portion 60 of the substrate 46, and fourth, fifth, and sixth seams 104-4, 104-5, 104-6 in the distal portion 62 of the substrate 46. The seams 104-1, 104-2, 104-3 may extend through the base layer 48. Where the substrate 46 includes the base layer 48 and both of the upper and lower laminate layers 50, 52, the seams 104-1, 104-2, 104-3 may extend through the base layer 48 and through one of the upper and lower laminate layers 50, 52. Where the substrate 46 includes the base layer 48 and one of the upper and lower laminate layers 50, 52, the seams 104-1, 104-2, 104-3 may extend through only the base layer 48. The seams 104-1, 104-2, . . . 104-n may extend from the lateral peripheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100. In this regard, the seams 104-1, 104-2, 104-3 may extend in a direction substantially parallel (+/−5 degrees) to the proximal peripheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82, 96.

With continued reference to FIGS. 4A and 4B, the shelf 18 may further include, or otherwise define, a first fold 106-1, a second fold 106-2 spaced apart from the first fold 106-1, and a third fold 106-3 spaced apart from the first and second folds 106-1, 106-2. It will be appreciated that the shelf 18 may include more or less than three folds within the scope of the present disclosure. In this regard, the number “n” of folds 106-1, 106-2, . . . 106-n may equal the number of seams 104-1, 104-2, . . . 104-n. Where the substrate 46 includes the base layer 48 and both of the upper and lower laminate layers 50, 52, the folds 106-1, 106-2, 106-3 may be formed in the one of the upper and lower laminate layers 50, 52 which does not include the seams 104-1, 104-2, 104-3. Where the substrate 46 includes the base layer 48 and one of the upper and lower laminate layers 50, 52, the folds 106-1, 106-2, 106-3 may be formed in that one of the upper and lower laminate layers 50, 52. The folds 106-1, 106-2, 106-3 may extend from the lateral peripheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100. In some implementations, the folds 106-1, 106-2, 106-3 extend in a direction substantially parallel (+/−5 degrees) to the proximal peripheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82, 96. In this regard, each fold 106-1, 106-2, . . . 106-n may be aligned with one of the seams 104-1, 104-2, . . . 104-n.

With reference to FIGS. 4 and 14A-14D, a method of manufacturing any component of shelf section 12-1, 12-2, . . . 12-n (i.e, shelf 18, lateral leg 20, medial leg 22, and backer 24) of the furniture unit 10 will now be described. The component of shelf section 12-1, 12-2, . . . 12-n may be manufactured from the substrate 46 having a thickness T extending between an upper surface (e.g., upper surface 74) and a lower surface (e.g., lower surface 90). The thickness T may be between two millimeters and ten millimeters. In some implementations, the thickness T may be substantially equal to five millimeters.

With particular reference to FIG. 14A, the method may include providing a tool 200 (e.g., a router, a blade, a bit, etc.) and using the tool to form a plurality of primary channels 202 in the substrate 46, e.g, by miter cutting the plurality of primary channels 202 in the substrate 46. In this regard, the number and location of the primary channels 202 may correspond to the number and location of the seams 104-1, 104-2, . . . 104-n or the number and location of the folds 106-1, 106-2, . . . 106-n. The tool 200 may include a male portion 203 and a female portion 205 opposite the male portion 203. As illustrated, in some configurations, the male portion 203 defines a convex profile and the female portion 205 defines a concave profile. It will be appreciated, however, that the male and female portions 203, 205 may define other profiles (e.g., triangular, rectangular, etc.) within the scope of the present disclosure. In this regard, the size and shape of the male portion 203 may correspond to, or otherwise be the same as, the size and shape of the female portion 205. Accordingly, as illustrated in FIG. 14A, the primary channels 202 may be defined by a first channel wall 204 having a male portion 207 formed by the female portion 205 of the tool 200, and a second channel wall 206 having a female portion 209 formed by the male portion 203 of the tool 200.

The first and second channel walls 204, 206 may extend through a majority of the thickness T of the substrate 46. For example, the first and second channel walls 204, 206 may extend through between approximately seventy percent of the thickness T of the substrate 46 and ninety-nine percent of the thickness T of the substrate 46. In some implementations, the first and second channel walls 204, 206 may extend through an entirety of the base layer 48 and through an entirety of the lower laminate layer 52. In this regard, the first and second channels walls 204, 206 may define a common edge 208 adjacent the lower surface 76 of upper laminate layer 50, and have an angle α therebetween. The angle α may be between about fifteen degrees and about one hundred sixty-five degrees. As illustrated in FIG. 14A, in some implementations, the angle α is substantially equal to ninety degrees.

With continued reference to FIG. 14A, the method may further include providing a tool 210 and forming one or more secondary channels 212 in the substrate 46. As illustrated in FIG. 14A, the secondary channels 212 may extend through the lower laminate layer 52 to expose the lower surface 56 of the base layer 48. In this regard, forming the secondary channels 212 may include removing a portion of the lower laminate layer 52. The secondary channels 212 may extend from the lateral peripheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100.

With reference to FIG. 14B, the method may also include folding the substrate 46 such that each first channel wall 204 of primary channel 202 engages the second channel wall 206 of the same of primary channel 202 to define a corresponding seam 104-n and fold 106-n. In this regard, the female portion 209 of each primary channel 202 may receive the male portion 207 of such primary channel 202. For example, the method may include performing a plurality of folding operations to define the plurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds 106-1, 106-2, . . . 106-n. In this regard, each fold 106-1, 106-2, . . . 106-n may define, or otherwise act as, a hinge for folding the substrate 46. Accordingly each fold 106-1, 106-2, . . . 106-n may be referred to herein as a hinge 106-1, 106-2, . . . 106-n. As illustrated in FIGS. 4A and 4B, in some implementations, the folding operations, and the plurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds 106-1, 106-2, . . . 106-n defined thereby, forms a hollow proximal support 214 at the proximal portion 60 of the substrate 46 and a hollow distal support 216 at the distal portion 62 of the substrate 46. The hollow proximal support 214 and/or the hollow distal support 216 may define a polygonal cross section extending from the lateral peripheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100. For example, the hollow proximal support 214 and the hollow distal support 216 may define a rectangular (e.g., square) cross section extending from the lateral peripheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100. In this regard, the upper surface 74 of the upper laminate layer 50 may include a first portion 218 and a second portion 219. The first portion 218 may extend from the proximal peripheral surface 80 to a first seam 104-1, and the second portion 219 may extend from the first seam 104-1 to a second seam 104-2. The first portion 218 and the second portion 219 may define an angle θ therebetween. The angle θ may be between about fifteen degrees and about one hundred sixty-five degrees. As illustrated in FIGS. 4 and 14B, in some implementations, the angle θ is substantially equal to ninety degrees.

With reference to FIG. 14C, folding the substrate 46 may also include engaging the proximal peripheral surfaces 64, 80, or 94 or the distal peripheral surfaces 66, 82, or 96 with the upper surface 54 of the base layer 48 or with the lower surface 56 of the base layer 48. In particular, folding the substrate 46 may include positioning the proximal peripheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82, 96 within one of the secondary channels 212 such that the proximal peripheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82, 96 engage the upper surface 54 or the lower surface 56 of the base layer 48. In this regard, the proximal peripheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82, 96 may define an angle β relative to one or more of the upper surfaces 54, 74, 88 or the lower surfaces 56, 76, 90. For example, the proximal peripheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82, 96 may define an angle β relative to the lower surface 90. The angle β may be between about ninety degrees and about one hundred eighty degrees. For example, if the hollow support portion 214 defines a rectangle the angle β may be substantially equal to ninety degrees. If the hollow support portion 214 defines a triangle the angle β may be greater than ninety degrees. In some implementations, if the hollow support portion 214 defines a triangle, the angle β may be substantially equal to one hundred twenty degrees.

In some implementations, engaging the proximal peripheral surfaces 64, 80, or 94 or the distal peripheral surfaces 66, 82, or 96 with the upper surface 54 of the base layer 48 or with the lower surface 56 of the base layer 48 may also include coupling the proximal peripheral surfaces 64, 80, or 94 or the distal peripheral surfaces 66, 82, or 96 with the upper surface 54 of the base layer 48 or with the lower surface 56 of the base layer 48 using an adhesive or other suitable technique.

As illustrated in FIGS. 4A and 4B, in some implementations, folding the substrate 46 to form the hollow proximal support 214 and/or the hollow distal support 216 includes folding the proximal portion 60 in a counterclockwise direction and folding the distal portion 62 in a clockwise direction.

With continued reference to FIG. 14C, the method may also include forming one or more apertures 220 through the substrate 46 and placing a primary connector 222 in each of the one or more apertures 220. For example, the method may include forming the one or more apertures 220 through the hollow proximal support 214 or the hollow distal support 216. The primary connector 222 may include a cross-dowel having an aperture 224 formed therein.

With reference to FIG. 14D, the method may further include coupling the shelf 18 to the lateral leg 20 or the medial leg 22. In some implementations, the method may include coupling a secondary connector 226 to each of the primary connectors 222 to couple the shelf 18 to the lateral leg 20 and the medial leg 22. For example, the method may include extending the secondary connectors 226 through the lateral leg 20 or the medial leg 22 and into the aperture 224 of the primary connector 222. In some implementations, extending the secondary connector 226 into the aperture 224 of the primary connector 222 includes threadably engaging the secondary connector 226 with the primary connector 222 within the aperture 224.

With reference to FIG. 5, another shelf 18 a for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 a may be substantially similar to that of the shelf 18, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “a”) are used to identify those features that have been modified.

The shelf 18 a may include the hollow proximal support 214 and a hollow distal support 216 a. As illustrated in FIG. 5, the hollow proximal support 214 and the hollow distal support 216 a may be disposed on opposite sides of the shelf 18 a. In this regard, folding the substrate 46 to form the hollow proximal support 214 may include folding the proximal portion 60 in a counterclockwise direction, and folding the substrate 46 to form the hollow distal support 216 a may include folding the distal portion 62 in a counterclockwise direction.

With reference to FIG. 6, another shelf 18 b for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 b may be substantially similar to that of the shelf 18, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “b”) are used to identify those features that have been modified.

The shelf 18 b may include a hollow support 216 b extending from the proximal portion 60 to the distal portion 62 of the substrate 46. In this regard, folding the substrate 46 to form the hollow support 216 b may include folding the proximal portion 60 in a counterclockwise direction, or folding the distal portion 62 in a clockwise direction, such that the proximal peripheral surfaces 64, 80, or 94 are disposed adjacent the distal peripheral surfaces 66, 82, or 96.

With reference to FIGS. 7A and 7B, another shelf 18 c (FIG. 7A) formed from the substrate 46, and for use with the assembly 10, is shown. The structure, function, and method of manufacturing the shelf 18 c may be substantially similar to that of the shelf 18 b, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “c”) are used to identify those features that have been modified.

The substrate 46 of the shelf 18 c may include the hollow support 216 b extending from the proximal portion 60 to the distal portion 62 of the substrate 46, and one or more covers 227. The cover 227 may engage a portion 228 of the lateral peripheral surfaces 68, 84, or 98 or a portion 228 of the medial peripheral surfaces 70, 86, or 100. As illustrated in FIG. 7B, in some implementations, the shelf 18 c may have two covers 227; one cover 227 may engage a portion 228 of the lateral peripheral surfaces 68, 84, or 98 and the other cover 227 may engage a portion 228 of the medial peripheral surfaces 70, 86, or 100. In this regard, in these implementations, the shelf 18 c may have the appearance of a solid piece (e.g., a solid piece of wood) without any openings. The substrate 46 may further include a fold 230 that may be formed in one of the upper and lower laminate layers 50, 52 such that one of the upper surfaces 54, 74, 88 or one of the lower surfaces 56, 76, 90 engages the portion 228 of the lateral peripheral surfaces 68, 84, or 98 or the medial peripheral surfaces 70, 86, or 100. In some implementations, the shelf 18 c may be utilized as a ceiling panel or baffle.

In other implementations, the shelf 18 c may be formed without one or both of the covers 227, or without one or more of the seams 104-1, 104-2, . . . 104-n, such that the shelf 18 c defines a four-sided construct or a five-sided construct in which each side defines a ninety degree angle relative to any adjacent sides. For example, with reference to FIGS. 7C and 7D, a five-sided ceiling baffle 18 c′ (FIG. 7D), formed from the substrate 46, is shown. The structure, function, and method of manufacturing the ceiling baffle 18 c′ may be substantially similar to that of the shelf 18 c, apart from any exceptions described below and/or shown in the Figures. In this regard, the substrate 46 may define a ceiling baffle 18 c′ having an opening 229 into the hollow support 216 c′.

With reference to FIG. 8, another shelf 18 d for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 d may be substantially similar to that of the shelf 18, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “d”) are used to identify those features that have been modified.

The shelf 18 d may include a support 216 d defining a corrugated construct extending from the proximal portion 60 to the distal portion 62 of the substrate 46. In this regard, folding the substrate 46 to form the support 216 d may include folding one or more portions of the substrate in a clockwise direction and a counterclockwise direction, such that one of the upper surfaces 54, 74, 88 or one of the lower surfaces 56, 76, 90 engages another one of the upper surfaces 54, 74, 88 or one of the lower surfaces 56, 76, 90. As illustrated in FIG. 8, folding the substrate 46 may include directly engaging various portions of the lower surface 56 of the base layer 48 with various other portions of the lower surface 56 of the base layer 48. In other implementations, folding the substrate 46 may include directly engaging various portions of the upper surface 54 of the base layer 48 with various other portions of the upper surface 54 of the base layer 48

With reference to FIG. 9, another shelf 18 e for use with the furniture unit 10 is shown. The structure, function, and method of manufacturing the shelf 18 e may be substantially similar to that of the shelves 18 and 18 b, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “e”) are used to identify those features that have been modified. While article 18 e is generally shown and described herein as being a “shelf 18 e,” it will be appreciated that article 18 e may be utilized in various ways within the scope of the present disclosure. For example, shelf 18 e may be utilized as a “shelf” for a bed. In this regard, the shelf 18 e may be utilized, and referred to herein, as a bedrail.

The shelf 18 e is a variation of the shelves 18 and 18 b shown in FIGS. 4 and 6, including a hollow proximal support 214 e and the hollow distal support 216 b, and excluding lower laminate layer 52. In particular, the shelf 18 e may include the hollow support 216 b extending from the proximal portion 60 to the distal portion 62 of the substrate 46. Folding the substrate 46 may include forming the hollow proximal support 214 e by folding the proximal portion 60 in a counterclockwise direction, and forming the hollow distal support 216 b by folding the substrate 46 in a clockwise direction from the proximal portion 60 to the distal portion 62 such that the proximal peripheral surfaces 64, 80 are disposed adjacent the distal peripheral surfaces 66, 82. In some implementations, the proximal peripheral surfaces 64, 80 and the distal peripheral surfaces 66, 82 engage the lower surface 56 of the base layer 48. In this regard, the upper surface 74 of the upper laminate layer 50 may include a first portion 232 (e.g., a forward portion) extending from a first seam 104-1 to the proximal peripheral surfaces 64, 80, and a second portion 234 (e.g., a rearward portion) extending from a second seam 104-2 to the distal peripheral surfaces 66, 82. The first portion 232 of the upper surface 74 may engage the second portion 234 of the upper surface 74. In some implementations, the first portion 232 of the upper surface 74 is attached to the second portion 234 of the upper surface 74. For example, the the first portion 232 of the upper surface 74 may be coupled to the second portion 234 of the upper surface 74 with an adhesive or other suitable fastening technique. The substrate 46 of shelf 18 e also may include lower laminate layer 52 such that the proximal peripheral surfaces 64, 80, or 94 are disposed adjacent the distal peripheral surfaces 66, 82, or 96; and in some implementations, the proximal peripheral surfaces 64, 80, or 94 and the distal peripheral surfaces 66, 82, or 96 engage the lower surface 90 of the lower laminate layer 52. In some implementations, the proximal peripheral surfaces 64, 80, or 94 and the distal peripheral surfaces 66, 82, or 96 are attached to the lower surface 90 of the lower laminate layer 52.

With reference to FIG. 10, a bedrail 18 f is shown. The structure, function, and method of manufacturing the bedrail 18 f may be substantially similar to that of the shelves 18, 18 b, 18 e, etc. apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “f”) are used to identify those features that have been modified. While article 18 f is generally shown and described herein as being a “bedrail 18 f,” it will be appreciated that article 18 f may be utilized in various ways within the scope of the present disclosure. For example, the bedrail 18 f may be utilized as a “shelf” for use with the furniture unit 10.

The bedrail 18 f is a variation of the shelf 18 e shown in FIG. 9, including a hollow proximal support 214 f and a hollow distal support 216 f. In some implementations, the bedrail 18 f, like the shelf 18 e, excludes the lower laminate layer 52. In other implementations, the bedrail 18 f, like the shelf 18, includes the lower laminate layer 52. In particular, the bedrail 18 f may include the hollow support 216 f extending from the proximal portion 60 to the distal portion 62 of the substrate 46.

Folding the substrate 46 may include forming the hollow proximal support 214 f by folding the proximal portion 60 in a counterclockwise direction, and forming the hollow distal support 216 f by folding the substrate 46 in a clockwise direction from the proximal portion 60 to the distal portion 62 such that the proximal peripheral surfaces 64, 80 face a first direction and the distal peripheral surfaces 66, 82 face a second direction opposite (e.g., approximately 180 degrees offset) the first direction. The first portion 232 may extend from the first seam 104-1 to a third seam 104-3 f and from the third seam 104-3 f to the proximal peripheral surfaces 64, 80, and the second portion 234 may extend from the second seam 104-2 to a fourth seam 104-4 f and from the fourth seam 104-4 f to the distal peripheral surfaces 66, 82. In particular, the first portion 232 may extend in the first direction from the third seam 104-3 f to the proximal peripheral surfaces 64, 80, and the second portion 234 may extend in the opposite second direction from the fourth seam 104-4 f to the distal peripheral surfaces 66, 82.

A portion of the upper surface 74 of the upper laminate layer 50, as well as the proximal peripheral surfaces 64, 80 and the distal peripheral surfaces 66, 82, may engage the lower surface 56 of the base layer 48, while the first portion 232 of the upper surface 74 may engage the second portion 234 of the upper surface 74. In some implementations, the first portion 232 of the upper surface 74 is attached to the second portion 234 of the upper surface 74. For example, the first portion 232 of the upper surface 74 may be coupled to the second portion 234 of the upper surface 74 with an adhesive or other suitable fastening technique.

As previously described, the substrate 46 of the bedrail 18 f also may include lower laminate layer 52 (not shown) such that the proximal peripheral surfaces 64, 80, or 94 face in a direction opposite the distal peripheral surfaces 66, 82, or 96; and in some implementations, the proximal peripheral surfaces 64, 80, or 94 and the distal peripheral surfaces 66, 82, or 96 engage the lower surface 90 of the lower laminate layer 52.

With reference to FIG. 11, a bedrail 18 g is shown. The structure, function, and method of manufacturing the bedrail 18 g may be substantially similar to that of the bedrail 18 f apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “g”) are used to identify those features that have been modified. While article 18 g is generally shown and described herein as being a “bedrail 18 g,” it will be appreciated that article 18 g may be utilized in various ways within the scope of the present disclosure. For example, the bedrail 18 g may be utilized as a “shelf” for use with the furniture unit 10.

The bedrail 18 g is a variation of the bedrail 18 f shown in FIG. 10, including the hollow distal support 216 f. In some implementations, the bedrail 18 g, like the bedrail 18 f, excludes the lower laminate layer 52. In other implementations, the bedrail 18 g, like the bedrail 18 f, includes the lower laminate layer 52. In particular, the bedrail 18 g may include the hollow support 216 f extending from the proximal portion 60 to the distal portion 62 of the substrate 46. Folding the substrate 46 may include forming the hollow distal support 216 f by folding the substrate 46 in a clockwise direction from the proximal portion 60 to the distal portion 62 such that the proximal peripheral surfaces 64, 80 face a first direction and the distal peripheral surfaces 66, 82 face a second direction opposite (e.g., approximately 180 degrees offset) the first direction. In this regard, the distal peripheral surfaces 66, 82 and a portion of the upper surface 74 of the upper laminate layer 50 may engage the lower surface 56 of the base layer 48, while the second portion 234 of the upper surface 74 may be exposed. In some implementations, the upper surface 74 of the upper laminate layer 50 is attached to the lower surface 56 of the base layer 48. For example, the upper surface 74 of the upper laminate layer 50 may be coupled to the lower surface 56 of the base layer 48 with an adhesive or other suitable fastening technique. In some implementations, the proximal peripheral surfaces 64, 80 are aligned (e.g., flush or coplanar) with the second portion 234 of the upper surface 74.

As previously described, the substrate 46 of the bedrail 18 g also may include lower laminate layer 52 (not shown) such that the proximal peripheral surfaces 64, 80, or 94 face in a direction opposite the distal peripheral surfaces 66, 82, or 96; and in some implementations, the distal peripheral surfaces 66, 82, or 96 engage the lower surface 90 of the lower laminate layer 52.

With reference to FIG. 12, a bedrail 18 h is shown. The structure, function, and method of manufacturing the bedrail 18 h may be substantially similar to that of the bedrail 18 f apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features, while like reference numerals containing letter extensions (i.e., “h”) are used to identify those features that have been modified. While article 18 h is generally shown and described herein as being a “bedrail 18 h” it will be appreciated that article 18 h may be utilized in various ways within the scope of the present disclosure. For example, the bedrail 18 h may be utilized as a “shelf” for use with the furniture unit 10.

The bedrail 18 h is a variation of the bedrail 18 f shown in FIG. 10, including the hollow proximal support 214 f and a hollow distal support 216 h. In some implementations, the bedrail 18 h, like the bedrail 18 f, excludes the lower laminate layer 52. In other implementations, the bedrail 18 h, like the bedrail 18 f, includes the lower laminate layer 52. In particular, the bedrail 18 f may include the hollow support 216 h extending from the proximal portion 60 to the distal portion 62 of the substrate 46. Folding the substrate 46 may include forming the hollow distal support 216 h by folding the substrate 46 in a clockwise direction from the proximal portion 60 to the distal portion 62 such that the proximal peripheral surfaces 64, 80 face in a direction opposite (e.g., approximately 180 degrees offset) the distal peripheral surfaces 66, 82. The first portion 232 may extend from the first seam 104-1 to the proximal peripheral surfaces 64, 80, and the second portion 234 may extend from the second seam 104-2 to the distal peripheral surfaces 66, 82. A portion of the upper surface 74 of the upper laminate layer 50, as well as the proximal peripheral surfaces 64, 80 and the distal peripheral surfaces 66, 82, may engage the lower surface 56 of the base layer 48, while the first portion 232 of the upper surface 74 may engage the second portion 234 of the upper surface 74.

In some implementations, the bedrail 18 h includes a plurality of seams 104-3 h, 104-4 h, . . . 104-nh disposed between the second seam 104-2 and the proximal portion 60 of the substrate 46. As illustrated in FIG. 12, in some implementations, the bedrail 18 h may include three seams 104-nh. It will be appreciated, however, that the bedrail 18 h may include more or less than three seams 104-nh within the scope of the present disclosure. In forming the hollow distal support 216 h by folding the substrate 46 in a clockwise direction, as previously described, from the proximal portion 60 to the distal portion 62, a portion of the upper surface 74 of the upper laminate layer 50, and a portion of the lower surface 56 of the substrate 46, may define a multi-sided shape. In this regard, a portion of the upper surface 74 and a portion of the lower surface 56 may each define a portion of a polygon. For example, a portion of the upper surface 74 and a portion of the lower surface 56 may each define a plurality (e.g., three) of sides of a polygon. For example, as illustrated in FIG. 12, a portion of the upper surface 74 and a portion of the lower surface 56 may define a plurality of sides of a hexagon, an octagon, a decagon, or other similar polygon extending between the second seam 104-2 and another of the seams 104-3 n. In this regard, if the portion of the upper surface 74 and the portion of the lower surface 56 define a plurality of sides of an octagon, the angle defined by adjacent seams of the plurality of seams 104-3 h, 104-4 h, . . . 104-nh may be substantially equal to ninety degrees. The portion of the upper surface 74 may be substantially parallel to the portion of the lower surface 56. In this regard, depending on the number of seams 104-3 n, the portion of the upper surface 74 and the portion of the lower surface 56 may define, or otherwise resemble, a segmented arcuate shape (e.g., semi-cylindrical).

With reference to FIGS. 13A and 13B, a bedrail assembly 300 is shown. While article 300 is generally shown and described herein as being a “bedrail assembly 300,” it will be appreciated that article 300 may be utilized in various ways within the scope of the present disclosure. For example, the bedrail assembly 300 may be utilized as a “shelf” for use with the furniture unit 10.

The bedrail assembly 300 may include a splice member 302 and one or more of the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or one or more of the bedrails 18 f, 18 g, 18 h. In this regard, while the bedrail assembly 300 is generally shown and described as including two of the bedrails 18 f, it will be appreciated that the bedrails 18 f of the bedrail assembly 300 may be replaced with one or more of the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or one or more of the bedrails 18 f, 18 g, 18 h within the scope of the present disclosure. Accordingly, while article 300 is generally shown and described herein as being a “bedrail assembly 300” it will be appreciated that article 300 may be utilized in various ways within the scope of the present disclosure. For example, the bedrail assembly 300 may be utilized as a “shelf assembly” for use with the furniture unit 10.

The splice member 302 may be formed from wood, metal, polymer, or other suitable structural material and may define a cross-sectional shape that is substantially the same as a void defined by the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or the bedrails 18 f, 18 g, 18 h. For example, the cross-sectional shape of the splice member 302 may be substantially the same as the shape of the void defined by the hollow distal support 216 f of the bedrail 18 f. In this regard, the void may be defined by the lower surface 56 of the base layer 48. The cross-sectional size of the void defined by the surface 56 of the base layer 48 may be smaller or larger than the cross-sectional size of the splice member 302.

Assembling the bedrail assembly 300 may include placing the splice member 302 within the hollow distal support 216 f of two bedrails 18 f (e.g., FIG. 13A) and moving a first of the bedrails 18 f toward the second of the bedrails 18 f. For example, assembling the bedrail assembly 300 may include moving a first of the bedrails 18 f toward the second of the bedrails 18 f until an end 26 h of the first of the bedrails 18 f abuts an end 28 h of the second of the bedrails 18 f. If the cross-sectional size of the void defined by the surface 56 of the base layer 48 is smaller than the cross-sectional size of the splice member 302, the splice member 302 may be disposed within the void in a friction-fit arrangement. The splice member 302 can increase the strength and rigidity of the bedrails 18 f and the bedrail assembly 300.

The configuration of, and related methods of manufacturing, the furniture unit 10 described herein, including, for example, the various channels 202, and the seams 104-n and folds 106-n formed thereby, can allow a user to easily and efficiently manufacture the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e, the bedrails 18 f, 18 g, 18 h, the furniture unit 10, and the bedrail assembly 300 to have superior strength and durability.

With reference to FIG. 15, another furniture unit 410 is shown. While the furniture unit 410 is generally shown and described herein as being a table, it will be appreciated that the furniture unit 410, or parts thereof, may include, or otherwise be utilized as, other types of home or office furniture or fixtures (e.g., shelves, bed frames, desks, etc.) within the scope of the present disclosure. The structure, function, and method of manufacturing the furniture unit 410 may be substantially similar to that of the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e, the bedrails 18 f, 18 g, 18 h, the furniture unit 10, and the bedrail assembly 300, apart from any exceptions described below and/or shown in the Figures. Accordingly, the structure and/or function of similar features will not be described again in detail. In addition, like reference numerals are used hereinafter and in the drawings to identify like features.

The furniture unit 410 may include a shelf 418 and one or more legs 422 coupled to, or otherwise supported by, the shelf 418. The shelf 418 may be substantially similar to the shelf 18. With reference to FIGS. 16-18, the legs 422 may each define a substantially hollow construct extending from a proximal end 424 to a distal end 426 and including, or otherwise formed from, the substrate 46, including the base layer 48 and the upper laminate layer 50. With reference to FIGS. 17-19, the substrate 46 may further include a plurality of proximal segments 428-1, 428-2, . . . 428-n, a plurality of distal segments 430-1, 430-2, . . . 430-n, a proximal end segment 432, and a distal end segment 434. While the substrate 46 is generally shown and described herein as including four proximal segments 428-1, 428-2, 428-3, 428-4 and four distal segments 430-1, 430-2, 430-3, 430-4, it will be appreciated that the substrate 46 may include more or less than four proximal segments 428-1, 428-2, 428-3, 428-4 and four distal segments 430-1, 430-2, 430-3, 430-4 within the scope of the present disclosure.

As illustrated in FIG. 19, the substrate 46 may further include a plurality of the primary channels 202 and a plurality of secondary channels 436. As previously described, each primary channel 202 may be defined by the first channel wall 204, having one of the male portion 207 or the female portion 209, and the second channel wall 206 having the other of the male portion 207 or the female portion 209 and forming the common edge 208 with the first channel wall 204. In particular, each proximal segment 428-1, 428-2, . . . 428-n may include the first channel wall 204 disposed on a first side of the proximal segment 428-1, 428-2, . . . 428-n, and the second channel wall 206 disposed on a second side, opposite the first side, of the proximal segment 428-1, 428-2, . . . 428-n, such that the common edge 208 is disposed between adjacent pairs of the proximal segments 428-1, 428-2, . . . 428-n. As will be explained in more detail below, each proximal segment 428-1, 428-2, . . . 428-n may be hingedly coupled to an adjacent proximal segment 428-1, 428-2, . . . 428-n along the common edge 208. Each distal segment 430-1, 430-2, . . . 430-n may similarly include the first channel wall 204 disposed on a first side of the distal segment 430-1, 430-2, . . . 430-n, and the second channel wall 206 disposed on a second side, opposite the first side, of the distal segment 430-1, 430-2, . . . 430-n. Likewise, each of the proximal and distal end segments 432, 434 may include the first and second channel walls 204, 206 disposed on opposed first and second sides of the proximal and distal end segments 432, 434, and the first and second channel walls 204, 206 disposed on opposed third and fourth sides of the proximal and distal end segments 432, 434.

Each primary channel 202 may form an angle δ with an adjacent primary channel 202. In particular, each common edge 208 (FIGS. 14A and 20), disposed between two of the proximal segments 428-1, 428-2, . . . 428-n may form the angle δ with the common edge 208 disposed between another two of the proximal segments 428-1, 428-2, . . . 428-n. The angle δ may be between zero degrees (e.g., such that each primary channel 202, each common edge 208, or each first channel wall 204 is parallel with one or more others of the primary channels 202, common edges 208, or first channel walls 204) and eighty degrees. In some implementations, the angle δ is between one degree and ten degrees. In some implementations, the angle δ is substantially (e.g., +/−three degrees) equal to five degrees, such that a distance between the first and second channel walls 204, 206 of each proximal segment 428-1, 428-2, . . . 428-n decreases in the direction extending from the distal end 426 towards the proximal end 424.

Each secondary channel 436 may be defined by a first channel wall 438, a second channel wall 440, and a floor 442 extending between the first and second channel walls 438, 440. In some implementations, the first channel wall 438, the second channel wall 440, and the floor 442 may define a substantially U-shaped channel 436. As illustrated in FIG. 19, the first channel wall 438 may be disposed on an end of one of the proximal segments 428-1, 428-2, . . . 428-n, while each second channel wall 440 may be disposed on an end of one of the distal segments 430-1, 430-2, . . . 430-n that is adjacent to one of the proximal segments 428-1, 428-2, . . . 428-n, such that the floor 442 extends between adjacent proximal segments 428-1, 428-2, . . . 428-n and distal segments 430-1, 430-2, . . . 430-n. As will be explained in more detail below, each distal segment 430-1, 430-2, . . . 430-n may be hingedly coupled to an adjacent proximal segment 428-1, 428-2, . . . 428-n along the floor 442.

Each secondary channel 436 may form an angle μ with an adjacent secondary channel 436. In particular, each first channel wall 438, second channel wall 440, or floor 442 disposed between one of the proximal segments 428-1, 428-2, . . . 428-n and one of the distal segments 430-1, 430-2, . . . 430-n may form the angle μ with the first channel wall 438, second channel wall 440, or floor 442 disposed between another adjacent ones of the proximal segments 428-1, 428-2, . . . 428-n and distal segments 430-1, 430-2, . . . 430-n. The angle μ may be between one hundred eighty degrees (e.g., such that each secondary channel 436, each floor 442, or channel wall 438, 440 is parallel with one or more others of the secondary channels 436, floors 442, or channel walls 438, 440) and two hundred sixty degrees. In some implementations, the angle μ is substantially (e.g., +/−three degrees) equal to one hundred eighty-five degrees.

With further reference to FIG. 19, each distal segment 430-1, 430-2, . . . 430-n may include one of the first channel wall 204 or the second channel wall 206, having one of the male portion 207 or the female portion 209, respectively. In some implementations, the first channel wall 204 of each distal segment 430-1, 430-2, . . . 430-n may be parallel to the second channel wall 206 of such distal segment 430-1, 430-2, . . . 430-n, and perpendicular to the secondary channel 436 of such distal segment 430-1, 430-2, . . . 430-n, such that each distal segment 430-1, 430-2, . . . 430-n is spaced apart from each adjacent distal segment 430-1, 430-2, . . . 430-n by a void 444.

With reference to FIGS. 16-18, in the assembled configuration, the leg 422 may include, or otherwise define, a plurality of proximal seams 448-1, 448-2, . . . 448-n, a plurality of distal seams 450-1, 450-2, . . . 450-n, a plurality of intermediate seams 452-1, 452-2, . . . 452-n, a plurality of proximal end seams 454-1, 454-2, . . . 454-n, a plurality of distal end seams 456-1, 456-2, . . . 456-n, a plurality of proximal folds 458-1, 458-2, . . . 458-n, a plurality of intermediate folds 462-1, 462-2, . . . 462-n, a proximal end fold 464-1, and a distal end fold 466-1. In particular, each first channel wall 204 of a primary channel 202 may engage the second channel wall 206 of the same of primary channel 202, in the manner previously described, to define a corresponding proximal seam 448-1, 448-2, . . . 448-n and proximal fold 458-1, 458-2, . . . 458-n. Similarly, each first channel wall 438 of a secondary channel 436 may engage the second channel wall 440 of the same secondary channel 436 to define a corresponding intermediate seam 452-1, 452-2, . . . 452-n and intermediate folds 462-1, 462-2, . . . 462-n. In some implementations, engagement of the first channel wall 438 with the second channel wall 440 may define a void 470 (FIG. 17) at the corresponding secondary channel 436. The first channel wall 204 of each distal segment 430-1, 430-2, . . . 430-n may engage the second channel wall 206 of an adjacent distal segment 430-1, 430-2, . . . 430-n, in the manner previously described, to define a corresponding distal seam 450-1, 450-2, . . . 450-n.

With reference to FIG. 17, in the assembled configuration, the leg 422 may include a proximal portion 472 and a distal portion 474. The proximal portion 472 may be formed by the proximal segments 428-1, 428-2, . . . 428-n and may define a varying cross-sectional area in a plane extending parallel to the intermediate seams 452-1, 452-2, . . . 452-n. For example, the proximal portion 472 may define a multi-sided pyramidal shape extending between the proximal and distal ends 432, 434 of the leg 422. In particular, outer surfaces 476 (FIG. 16) of proximal segments 428-1, 428-2, . . . 428-n may collectively define a pyramidal shape. Similarly, inner surfaces 477 (FIG. 17) of proximal segments 428-1, 428-2, . . . 428-n may collectively define a pyramidal shape. The distal portion 474 may be formed by the distal segments 430-1, 430-2, . . . 430-n and may define a uniform cross-sectional area (e.g., the same cross-sectional size and shape across the entire distal portion 474) in a plane extending parallel to the intermediate seams 452-1, 452-2, . . . 452-n. For example, the distal portion 474 may define a rectangular shape extending from the distal end 434 to the channel 436 of the leg 422. In particular, outer surfaces 478 (FIG. 16) of the distal segments 430-1, 430-2, . . . 430-n may collectively define a cuboid shape. Similarly, inner surfaces 479 (FIG. 17) of the distal segments 430-1, 430-2, . . . 430-n may collectively define a cuboid shape.

With reference to FIGS. 14A-14D and 20-22, a method of manufacturing and assembling the leg 422 will now be described. The method of manufacturing the leg 422 may be substantially similar to the previously-described method of manufacturing the shelf 18. Accordingly, certain aspects of manufacturing the leg 422 may not be described again in detail. With particular reference to FIGS. 14A and 20, the method may include using the tool 200 to form the primary channels 202 in the substrate 46 to define the plurality of proximal segments 428-1, 428-2, . . . 428-n in the manner previously described relative to the shelf 18. In this regard, the primary channels 202 may extend through the base layer 48 and terminate at or before the laminate layer 50.

As illustrated in FIG. 20, in some implementations, the substrate 46 includes a first portion 46 a having a plurality of primary channels 202 forming a first plurality of proximal segments 428-1, 428-2, . . . 428-n, and a second portion 46 b having a plurality of primary channels 202 forming a second plurality of proximal segments 428-1, 428-2, . . . 428-n. In this regard, while the substrate 46 is shown as including a first portion 46 a and a second portion 46 a, it will be appreciated that the substrate 46 may include any number of portions (e.g., 46 a, 46 b) within the scope of the present disclosure.

The primary channels 202 of the first plurality of proximal segments 428-1, 428-2, . . . 428-n may be formed such that a proximal end 480 a of the first plurality of proximal segments 428-1, 428-2, . . . 428-n of the first portion 46 a is disposed opposite a proximal end 480 b of the second plurality of proximal segments 428-1, 428-2, . . . 428-n of the second portion 46 b, and a distal end 482 a of the first plurality of proximal segments 428-1, 428-2, . . . 428-n of the first portion 46 a is disposed opposite a distal end 482 b of the second plurality of proximal segments 428-1, 428-2, . . . 428-n of the second portion 46 b. In other implementations, the method may include using the tool 200 to form primary channels 202 defining the plurality of distal segments 430-1, 430-2, . . . 430-n, the proximal end segment 432, and the distal end segment 434, as illustrated in FIG. 19. In this regard, the method may further include providing the tool 210 (e.g, a router, circular or reciprocating saw blade, or other suitable cutting tool) to form the secondary channels 436 in the substrate 46. The secondary channels 436 may extend through the base layer 48 and terminate at or before the laminate layer 50.

With reference to FIG. 21, the method may also include separating the first portion 46 a of the substrate 46 from the second portion 46 b of the substrate. For example, the method may include separating the first portion 46 a from the second portion 46 a by cutting or otherwise breaking the substrate 46 along one of the primary channels 202, such that a first wall 204 of one of the primary channels 202 defines a peripheral edge or surface of the portion 46 a or 46 b, and a second wall 206 of another of the primary channels 202 defines another peripheral edge or surface of the same portion 46 a or 46 b.

With reference to FIGS. 17 and 19, the method of assembling the leg 422 may also include applying an adhesive within one or more of the primary channels 202 or secondary channels 436. For example, the method may include applying an adhesive to the first or second channels walls 204, 206 or the male or female portions 207, 209 of the primary channels 202, or to the first channel wall 438, second channel wall 440, or floor 442 of the secondary channels 436. In some configurations, the method may include applying a polyvinyl acetate adhesive within the primary channels 202 and a polyurethane adhesive 486 within the secondary channels 436. In some implementations, the polyurethane adhesive 486 fills the void 470.

With reference to FIG. 22, the method may also include folding the first or second portion 46 a, 46 b of the substrate 46 such that each first channel wall 204 of a primary channel 202 engages the second channel wall 206 of the same of primary channel 202, to define the corresponding seams 448-n, 450-n, 454-n, 456-n and folds 458-n, 462-n, 464-1, 466-1. For example, the method may include performing a plurality of folding operations to define the plurality of seams 448-n, 450-n, 454-n, 456-n and folds 458-n, 462-n, 464-1, 466-1. Each fold 458-n, 462-n, 464-1, 466-1 may define, or otherwise act as, a hinge for folding the substrate 46. Accordingly each fold 458-n, 462-n, 464-1, 466-1 may be referred to herein as a hinge 458-n, 462-n, 464-1, 466-1. As illustrated in FIG. 17, upon folding the proximal segments 428-1, 428-2, . . . 428-n relative to the distal segments 430-1, 430-2, . . . 430-n at the secondary channels 436, the first and second channel walls 438, 440 and the floor 442 may define the void 470 having the adhesive 486 disposed therein. While the void 470 is illustrated as defining a substantially triangular cross-sectional shape, it will be appreciated that the void 470 may define other cross-sectional shapes (e.g., an isosceles trapezoid) within the scope of the present disclosure. In this regard, the cross-sectional shape of the void 470 may depend on the relationship between (i) the distance between the channel walls 438, 440 and (ii) the size and shape (e.g., angles δ, μ, length, etc.) of the leg 422.

In some implementations, the folding operations, and the plurality of seams 448-n, 450-n, 454-n, 456-n and folds 458-n, 462-n, 464-1, 466-1 defined thereby, forms a hollow intermediate member 488 (FIG. 22) defining a polygonal cross section. For example, as previously described, the intermediate member 488 may be formed by the proximal segments 428-1, 428-2, . . . 428-n and may define the intermediate member 488 having a cross-sectional area that varies (e.g., tapers) in a plane extending parallel to a plane defined by the intermediate seams 452-1, 452-2, . . . 452-n. For example, the intermediate member 488 may define a pyramidal shape extending between the proximal and distal ends 480 b, 482 b. In particular, the outer surfaces 476 of the proximal segments 428-1, 428-2, . . . 428-n may collectively define a pyramidal shape. In this regard, as illustrated in FIG. 22, in the folded configuration, the outer or inner surfaces 476, 477 of each proximal segment 428-1, 428-2, . . . 428-n may define a non-parallel angle relative to a longitudinal axis L extending between the proximal and distal ends 480 b, 482 b of the intermediate member 488 and relative to the others of the outer or inner surfaces 476, 477 of the proximal segments 428-1, 428-2, . . . 428-n. Similarly, each seam 448-n and corresponding fold 458-n may form a non-parallel angle with the others of the seams 448-n and folds 458-n respectively.

It will also be appreciated that, as previously described, the intermediate member 488 may include the distal portion 474 formed by the distal segments 430-1, 430-2, . . . 430-n and defining a cross-sectional area that is uniform (e.g., constant) from the proximal end 480 a to the distal end 482 a in a plane extending parallel to the plane defined by the intermediate seams 452-1, 452-2, . . . 452-n. For example, the distal portion 474 may define a rectangular shape extending partially between the proximal and distal ends 480 b, 482 b of the intermediate member 488. In particular, the outer surface 478 (FIG. 16) of the distal segments 430-1, 430-2, . . . 430-n may collectively define a cuboid shape. In this regard, in the folded configuration, the outer or inner surfaces 478, 479 of each distal segment 430-1, 430-2, . . . 430-n may define a parallel angle relative to the longitudinal axis L extending between the proximal and distal ends 480 b, 482 b of the intermediate member 488 and relative to the others of the outer or inner surfaces 478, 479 of the distal segments 430-1, 430-2, . . . 430-n. Similarly, each seam 450-n may form a parallel angle relative to the others of the seams 450-n. Accordingly, with reference to FIGS. 17 and 19, the method of manufacturing the leg 422 422, 422 i may include engaging each first channel wall 438 with the second channel wall 440 of the same secondary channel 436 to form the void 470, and engaging the first or second channel wall 204, 206 of one or more of the proximal segments 428-1, 428-2, . . . 428-n or distal segments 430-1, 430-2, . . . 430-n with the first or second channel wall 204, 260 of the proximal end segment 432 or the distal end segment 434.

With reference to FIGS. 16 and 23, the method may also include removing the proximal end 480 b or distal end 482 b of the intermediate member 488 to form a hollow furniture unit, such as the leg 422 (FIG. 16) or the leg 422 i (FIG. 23). For example, the method may including cutting the substrate 46 to remove the proximal end 480 b or the distal end 482 b. With reference to FIG. 15, the method may further include coupling the shelf 18 to the legs 422 or 422 i.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 

What is claimed is:
 1. A leg comprising: an outer surface; an inner surface opposite the outer surface; a first wall extending from the outer surface to the inner surface; a second wall coupled to the first wall and extending from the outer surface to the inner surface; a first seam formed in the inner surface; and a second seam spaced apart from the first seam and formed in the inner surface, the second seam forming a first non-parallel angle with the first seam and a second non-parallel angle with the first wall.
 2. The leg of claim 1, wherein the first non-parallel angle is equal to the second non-parallel angle.
 3. The leg of claim 2, wherein the first non-parallel angle is five degrees.
 4. The leg of claim 1, wherein the inner surface defines a multi-sided pyramidal shape.
 5. The leg of claim 1, wherein the first seam includes a first proximal portion and a first distal portion extending from the first proximal portion, and wherein the first proximal portion forms a third non-parallel angle with the first distal portion.
 6. The leg claim 5, wherein the second seam includes a second proximal portion and a second distal portion extending from the second proximal portion, and wherein the second proximal portion forms a fourth non-parallel angle with the second distal portion.
 7. The leg of claim 6, wherein the outer surface includes a proximal outer portion and a distal outer portion, the proximal outer portion extending between the first proximal portion and the second proximal portion, the distal outer portion extending between the proximal outer portion, the first distal portion, and the second distal portion, and wherein the proximal outer portion forms a fifth non-parallel angle with the distal outer portion.
 8. The leg of claim 7, wherein the proximal outer portion defines a pyramidal cross-sectional shape.
 9. The leg of claim 8, wherein the distal outer portion defines a shape having a uniform cross-sectional area.
 10. The leg of claim 1, wherein the outer surface defines a pyramidal shape.
 11. A leg extending from a proximal end to a distal end, the leg comprising: a first wall extending from the proximal end to the distal end; a second wall coupled to the first wall and extending from the proximal end to the distal end; a first seam spaced apart from the first wall and the second wall and extending from the proximal end to the distal end; a second seam spaced apart from the first seam, the first wall, and the second wall and extending from the proximal end to the distal end; and an outer surface including a first segment extending between the first wall and the first seam, a second segment extending between the first seam and the second seam, and a third segment extending between the second seam and the second wall, wherein the first segment, the second segment, and the third segment define a pyramidal cross-sectional shape extending from the proximal end to the distal end.
 12. The leg of claim 11, wherein the second seam forms a first non-parallel angle with the first seam and a second non-parallel angle with the first wall.
 13. The leg of claim 12, wherein the first non-parallel angle is equal to the second non-parallel angle.
 14. The leg of claim 13, wherein the first non-parallel angle is five degrees.
 15. The leg of claim 11, further comprising an inner surface opposite the outer surface and defining a multi-sided pyramidal shape.
 16. The leg of claim 11, wherein the first seam includes a first proximal portion and a first distal portion extending from the first proximal portion, and wherein the first proximal portion forms a first non-parallel angle with the first distal portion.
 17. The leg of claim 16, wherein the second seam includes a second proximal portion and a second distal portion extending from the second proximal portion, and wherein the second proximal portion forms a second non-parallel angle with the second distal portion.
 18. The leg of claim 17, wherein the outer surface includes a first distal outer portion extending from the first segment, a second distal outer portion extending from the second segment, and a third distal outer portion extending from the third segment, and wherein the first segment forms a third non-parallel angle with the first distal outer portion.
 19. The leg of claim 18, wherein the first, second, and third distal outer portions define a shape having a uniform cross-sectional area.
 20. A leg comprising a substrate including a first proximal segment, a second proximal segment, and a third proximal segment, the second proximal segment hingedly coupled to the first proximal segment along a first seam, the third proximal segment hingedly coupled to the second proximal segment along a second seam, the first seam forming a first non-parallel angle with the second seam.
 21. The leg of claim 20, wherein the first proximal segment is coupled to the third proximal segment along a third seam forming a second non-parallel angle with the second seam, the first non-parallel angle being equal to the second non-parallel angle.
 22. The leg of claim 21, wherein the first non-parallel angle is five degrees.
 23. The leg of claim 20, wherein the first proximal segment includes a first proximal outer surface, the second proximal segment includes a second proximal outer surface, and the third proximal segment includes a third proximal outer surface, and wherein the first, second, and third proximal outer surfaces define a varying cross-sectional area.
 24. The leg of claim 23, wherein the varying cross-sectional area defines a pyramid.
 25. The leg of claim 20, further comprising: a first distal segment hingedly coupled to the first proximal segment and having a first distal wall and a second distal wall parallel to the first distal wall; a second distal segment hingedly coupled to the second proximal segment and having a third distal wall and a fourth distal wall parallel to the third distal wall; and a third distal segment hingedly coupled to the third proximal segment and having a fifth distal wall and a sixth distal wall parallel to the fifth distal wall.
 26. The leg of claim 25, wherein the first distal wall is coupled to the sixth distal wall, the second distal wall is coupled to the third distal wall, and the fourth distal wall is coupled to the fifth distal wall.
 27. The leg of claim 25, wherein the first distal segment includes a first distal outer surface, the second distal segment includes a second distal outer surface, and the third distal segment includes a third distal outer surface, and wherein the first, second, and third distal outer surfaces defining a uniform cross-sectional area.
 28. The leg of claim 27, wherein the uniform cross-sectional area defines a rectangle.
 29. The leg of claim 25, further comprising a polyurethane adhesive disposed between the first distal segment and the first proximal segment.
 30. The leg of claim 25, further comprising an endcap coupled to one or more of the first distal segment, the second distal segment, or the third distal segment, such that the endcap, the first distal segment, the second distal segment, and the third distal segment define an enclosed leg.
 31. The leg of claim 20, wherein the substrate include a base layer and a laminate layer.
 32. The leg of claim 31, wherein the base layer defines a channel.
 33. The leg of claim 20, wherein the first proximal segment is coupled to the third proximal segment along a third seam forming a second non-parallel angle with the first seam. 